Assessment of Mechanical Recycling Potential of Plastic Waste from End-of-Life LFP Battery Cases

This study evaluated the feasibility of mechanical recycling of plastic waste recovered from the disassembly of end-of-life lithium iron phosphate battery cases. In particular, the work focused on the case fraction, corresponding to the outer battery envelope, which represents the largest share of the plastic waste by weight. A preliminary characterization was carried out to determine the physico-chemical properties of the material and assess its suitability for mechanical recycling. The polymer matrix was found to consist of polypropylene, with glass fibers and calcium carbonate as inorganic fillers, each present at 18 wt%. X-ray fluorescence and elemental analysis confirmed the absence of elements of concern and subsequently, recycled material processability was investigated, with particular attention to injection molding, the same technology used to manufacture the original battery cases. Rheological analyses confirmed that the material exhibits Newtonian rheological behavior, suitable for injection molding, as also supported by a melt flow index value equal to 7.5 g/10 min (230 °C, 2.16 kg). The material was then reprocessed, and the resulting specimens were subjected to mechanical tests, with impact energy equal to 30.5 kJ/m2 and flexural strength amounting to 36.8 MPa. Overall, the recycled material exhibited adequate processability and mechanical performance after one reprocessing step, suggesting its potential for high-value mechanical recycling.